Optimizing perishable chilled foods operations for a leading food retailer in South Africa

Project Objectives

The main objective was to align stores with their corresponding dispatch zones to ensure accurate order assembly and efficient combination of orders destined for nearby locations. Additionally, the goal was to minimize walking distance by positioning the picking grid closer to the staging area, creating a more direct path and reducing cross-flow, while maintaining minimal aisle congestion.

Client Overview

A fast-paced perishable cold chain flow-through operation serves 300 stores daily across South Africa. Engineered for continuous flow and multiple daily collection waves, this operation is highly specialized. With a pick-to-store process driven by incoming deliveries, there is no margin for delay—orders arrive constantly and must be picked and dispatched timeously to clear the floor for the next cycle.

Project Approach

• Document current operational processes and analyse historical data.
  
  

• Evaluate the required capacity.
  
  

• Identify and define operational challenges.
  
  

• Optimize the placement of order picking and staging areas to reduce walking distances and minimize aisle congestion.
  
  

• Enhance co-load staging placements to ensure faster dispatches.

Project Results

• Completed a successful redesign of the operational area.
  
  

• Significantly decreased travel distances for on-floor staff.
  
  

• Managed record throughput in December 2023 as a result of operational enhancements

Had a visit from some of the board and executive members today. We told them how well the tactical project you did with us has set us up for peak. They were super impressed.

" Thanks for helping us set a new record tonight "

Relevant Services

Operational Analysis & Design

Strategy Development